Quench for furnace type reactors



Feb. 12, 1957 R. c. HOWELL QUENCH FOR FURNACE TYPE REAcTo'Rs 2 She'ets-Sheet 1 Filed Jan. 15, 1951 INENTOR. R. c. HOWE u.

FIG. 3.

AT TO/PNEYS Feb. 12, 1957v R. c. HOWELL 2,781,251

QUENCH FOR FURNACE TYPE REACTORS Filed Jan. 15, 1951 2 Sheets-Sheet 2 A T TO/PNE Y5 United States Patent QUENCH FOR FURNACE TYPE REACTORS Robert C. Howell, Phillips, Tex., assignor to Phillips Petroleum Company, a corporation of Delaware Application January 15, 1951, Serial No. 206,033

3 Claims. (Cl. 23-277) This invention relates to an improved type of quench suitable for quenching of the efliuents from reactors, especially reactors of the furnace type. In another aspect it relates to means for coupling a ceramic lined pipe containing fluids at about 2000 F. or higher with an inexpensive metal pipe in which the fluids are at a temperature of about 1500 F. or lower. In another aspect it relates to a quench suitable for use with a carbon black furnace.

While this invention is adapted for use in a great number of situations, it was especially designed to be substituted for quench 6 in Figure 1 in the application of Paul B. Milam, Serial No. 136,737, filed January 4, 1950, now Patent No. 2,691,539. A quench is not essential to a carbon black furnace process at this point, but is preferable in order to reduce the expense of the original installation, and the expense of upkeep, because ordinary metal pipe cannot take high temperatures, at least over a long period of time, without danger of failure. Generally it is too expensive to extend the length of the ceramic lined pipe to the length necessary to allow the efiluents contained therein to cool down to a temperature compatible with inexpensive metal pipe. The present invention is particularly well adapted for use whenever a quench is employed in a carbon black furnace outlet as shown in the patent to Ayres 2,420,999 of May 27, 1947, to Krejci, 2,564,700 of August 21, 1951, and copending application Serial No. 577,180 filed February 10, 1945, and abandoned October 10, 1951. The present invention is also adapted for use as a quench for hot efiluents from pebble furnaces, or other types of reactors in which hydrocarbons or other liquids or gases are cracked, reformed or otherwise reacted, especially when pyrolysis is involved and particularly when the quench is desired in order to check the progress of the reaction at a certain point and thereby prevent the degradation of end products or the creation of unwanted products.

In the prior art it has been customary to place quench sprays for efliuents from high temperature refractory furnaces inside a water jacketed metal pipe attached to the outlet from said furnace. Such quenches are entirely satisfactory from the standpoint of the reaction process involved, but the water jacketed metal pipe has a very short life depending upon the temperatures involved and whether the water level ever accidently becomes too low or not. By eliminating the water jacket, the water cooling tower, low pressure water piping and valves, low pressure water pumps, and much other auxiliary equipment necessary to supply the water jacket with cool Water, are also eliminated. At the same time maintenance costs and the loss through breakdowns will be greatly reduced.

One object of this invention is to provide an improved quench for a hot effluents-forming reactor.

Another object is to provide means for coupling a refractory lined pipe to an inexpensive metal pipe and to cool the hot contents of the refractory pipe to a temperature compatible with long life for the inexpensive metal pipe.

Another object is to reduce the length of expensive pipe involved and replace it with a similar length of inexpensive pipe.

A further object is to provide a quench for rapidly bringing hot efiluents down below a temperature at which undesired reactions will occur, or be continued.

Another object is to provide a quench of simple, rugged, fool-proof construction, easily installed, easily removed, repaired, adjusted and replaced, and of simple and inexpensive construction.

Numerous other objects and advantages will be apparent to those skilled in the art upon reading the accompanying specification, claims and drawings.

Figure l is an elevational view with parts in section of an actual installation in a carbon black furnace plant of a preferred embodiment of the invention selected for illustrative purposes.

Figure 2 is an enlarged elevational view of the quench shown in Figure l, with parts broken away to show details of construction.

Figure 3 is a cross sectional view of the furnace and quench of Figure 1, showing a preferred means of attaching the two together.

Figure 4 is a cross-sectional view of the apparatus shown in Figure 2 taken along the line 3-3 looking in the direction indicated, with parts broken away to show details of construction.

Figure 5 is an elevational View of the details of construction of a suitable and preferred spray nozzle for use in the illustrative embodiment of the invention as shown in the other figures of the drawing.

Figure 6 is an enlarged sectional view of the head of the spray nozzle shown in Figure 5, showing details of construction.

Figure 7 is an elevational view of a modified form of quench embodying the present invention.

In Figure 2 a reactor generally designated as 11 is producing a reactant efiiuent which is to be conveyed through pipe 12. This hot efiluent may, for example, be produced by burning a hydrocarbon feed 13 with a free-oxygen containing gas feed 14 in the furnace 11 which may have one or more chambers 16 and 17, all as set forth in the above-cited patent and patent applications. The nature of reactor 11 is immaterial to the invention except for the fact that a hot gaseous effluent is emerging therefrom. The present invention comprises a quench section generally designated as 18 for connecting reactor 11 with pipe 12 for the purposes and objects set forth above, as will be explained further in the operation of the invention as described below.

Quench section 18 preferably comprises a refractory lined pipe section 19 provided with water supply pipes 23, and pipe connection 22.

Pipe 12 in the specific embodiment illustrated is then connected to pipe 23 and 24- by flexible joints 25 and 27 and thence by pipe 28 to header or collector manifold '29, but whether pipe 12 is connected to other pipes is immaterial so far as the present invention is concerned, being fully described and claimed in said pending application Serial No. 136,737 filed January 4, 1950, now Patent No. 2,691,539. Figure 1 has been chosen, however, to show a preferred embodiment of the invention in a specific environment in which it is highly successful.

In Figure 2 it will be noted that the pipe 22 is shown as fabricated of two reversed elbows 31 and 32, welded together at 33 and having flanges 34 and 35 welded to their terminal ends. At the same time it should be obvious that pipe connection 13 could be cast in one piece. It is desirable, for easy handling, to have a lift-ing lug 37 secured to pipe'iii, which is shown perforated for connec tion with a hoisting hook. In order to be able to inspect the interior of quench section 19, as well as the interior of the furnace or reactor 11, as it is coaxial therewith,

it is preferred to have an opening 38 with a removable cover 39 secured thereto.

A quench pipe section 19 comprises a metal pipe 41 having a flange 42 secured thereto for connection with flange 34 and a flange 43 secured thereto for connection with reactor 11. In the specific embodiment shown, flange 43 is so much larger than flange 42 that it is desirable to brace pipe 41 thereto with suitable gussets 44. The interior of pipe 41 is lined with a refractory pipe 46. Pipe 46 is provided with one or more holes 47, preferable a plurality thereof, for the reecption of spray nozzle 48, which are shown in more detail in Figures and 6. The axis of openings 47 is preferably not perpendicular to the axis of pipe 19, but they are inclined downstream at an angle preferably between 45 and 87% between the respective axes. In order to secure the spray head 48 in place it is preferred to secure threaded nipples or supports 49 to pipe 41 so that the spray nozzle may be positioned quickly and removed quickly by connecting coupling 51 thereto.

In order to facilitate the rapid adjustment of spray head 48, connecting pipes 52 are made of flexible hose material, such as any suitable rubber, or rubber-like composition, steam hose. Such rubber steam hose may be internally or externally armored, or contain various woven wire or cotton sleeves therein as common in such hose, and is connected to coupling 51 by any approved and conventional type of steam hose connector 53.

In order to supply quench fluid to spray nozzle 48 a suitable water manifold 54 is made up of standard pipe connections, or welded pipes (not shown) which may be separately supported (not shown) or clamped to flange 43 by suitable conventional clamp means 56. An inlet connection 57 is provided along with one outlet connection 58 for each spray head 48, preferably controlled by a shut-off valve 59.

If it is desired to increase the cooling capacity of pipe 12 it may be provided with one or more cooling fins 61 (shown in Figure 2 but not in Figure 1). While not essential to the practice of the invention, a preferred form of construction at the point of attachment of the quench section 19 and reactor 11 is shown in Figure 3. It will be noted that the reactor is lined with refractory bricks 62. In the specific carbon black furnace illustrated the inner course of these bricks is preferably Korundal a trademark name for a very good refractory material. Refractory pipe 63 has an annular rabbet 64 forming an overlapping annular shoulder 66 which overlaps the Sillimanite refractory lining 46, which is a trademark name for another suitable refractory material. No details as to the composition of these refractory materials are given because the invention does not depend thereon because any suitable refractory materials may be employed, and any engineer can select the same. The space between refractory bricks 62 and plate 43 is preferably plastered with a thin layer of Insulag 65, a trademark term for a suitable refractory mortar, which also could consist of 50% Portland cement and 50% asbestos fibre mixed with suflicient water to form a paste, because it is not at a very hot point, being near the exterior, atmosphere-cooled surface.

Figure 4 is a cross-sectional view of Figure 2 and needs no further explanation. However, it should be noted that the entire device shown in Figure 4 can be employed in the position shown or can be rotated around its central axis any number of degrees whatsoever. In fact in many commercial installations the apparatus is rotated 45 clockwise from the position shown in Figure 4. This changes the stresses on the gusset plates 44 and moves the points of injection of water spray to 45 from the vertical and horizontal, but makes no material difference in the operation of the device.

In Figure 5 is shown the assembly detail of the spray head 48. The present coupling member that forms the body of 48 is made up of a pipe cap 67 to which is welded a pipe coupling 68 and'a second pipe coupling 69 is welded into a coaxial position inside body 48. But probably when larger numbers are made this head will be cast in one piece. It is provided with internal screw threads 71 to connect to coupling 53, with internal threads 72 to connect with nipple or spout 49, and preferably has internal threads 73 for supporting axial nipple 74 which has the spray nozzle head 76 fastened thereto.

Head 76 may be any standard type of spray nozzle, as any nozzle which gives conical or diffusive spray is satisfactory. Such a nozzle is shown in Figure 6, and contains perforated diaphragm 77 which breaks up the liquid flowing therethrough into a diffuse spray.

Figure 7 shows a modification of the invention illustrated in Figure 2 and like numbers are used for like parts which will not be described. This modification is adapted to use on a reactor which does not have a large end suitable for receiving end plate 43 of Figure 2, but instead is connected to flange 78. There being no end plate 43, the manifold 54 is clamped on by means of clamps 79 attached to lugs 81 which are secured to the housing 41.

The pipe may have a reducing portion 82 therein. It is preferable to provide a thermocouple well 83 in the pipe to determine the temperature from a thermocouple placed in the well in indirect heat exchange with the etfluents in the well, as such temperature indicates the degree of quench, and thereby indicates whether the sprays 48 are operating properly. Obviously thermocouple well 83 can be used in the device shown in Figure 2.

Operation In the operation of the device the hot effluent gases from the reactor enter section 19, where they will not overheat metal pipe 41 because metal 41 is air-cooled and is cooled by radiation while refractory lining 46 protects the same by its low heat conductivity, while the hot gases are cooled by Water spray injected through nozzles 48, the nozzles spreading the water out throughout the gases. The water droplets in evaporating cool the gases by an amount equal to their latent heat of vaporization. If there is substantial rotation of the hot eflluent gases from the reactor 11, as there is in many, but not all, carbon black furnaces, the wall of the metal pipe 31 will have its inner surface blanketed by water and water vapor since these are the heaviest parts of the effluent and will be thrown outward by the centrifugal force of the rotating efiluent issuing from the reactor. As pointed out above, the elimination of any water jacket reduces the amount of equipment needed considerably, and minimizes the cost and amount of time lost due to leaks or breakdowns.

A typical quench of this nature cools the eflluent gases from about 2000 F., or above, to about 1500 F., or below, and enables the use of inexpensive carbon steel as the metal for pipes 12, 31 and 32, which except for the spray would become red hot.

In such a quench the spray nozzles often become unadjusted, eroded out, fouled shut, plugged, etc. This results in improper quench which can be observed by removing cap 39, but preferably is first observed by measuring the temperature through thermocouple well 83. Diaphragm 77 of Figure 6 may become eroded or blow out, in which case too great cooling occurs, or it may become blocked with dirt, in which case overheating occurs. In any instance an observation through opening 38, while running or while shut down, will show which spray is at fault, and for that matter all of the sprays can be removed one at a time by closing their respective valves 59 and unscrewing them at 51 without shutting down the furnace, which is the chief reason for employing a flexible hose connection 52.

While I have shown a preferred embodiment of my invention, the invention obviously is not limited thereto, but is as defined in the following claims.

Having described my invention, 1 claim:

1. In the combination of a furnace and a liquid spray quench, said furnace having a ceramic refractory chamber adapted to carry out pyrolytic conversion of hot gases therein, said chamber being directly connected to discharge said hot converted gases into said quench, and a liquid dispenser disposed to spray liquid into said gases in said quench, the improvement in which said quench comprises a ceramic refractory first conduit section directly connected to said chamber to receive said hot gases therefrom, a heat conducting uninswlated metal second conduit section directly connected to said first section to receive said gases therefrom, said ceramic refractory in said first section being perforated, and said liquid dispenser comprising a metal liquid supply conduit and metal spray head located in said perforation in said perforated ceramic refractory and disposed and directed to spray said liquid through said perforation into and through said first section and out the discharge end thereof into said second section without said liquid spray contacting said ceramic refractory, whereby cracking and spalling of said ceramic refractory due to impingement of sprayed liquid on the same is substantially eliminated, and whereby the overall length of said furnace and quench, and thereby the pyrolytic reaction time therein, is reduced.

2. In the combination of a carbon black furnace and a liquid spray quench, said furnace having a ceramic refractory chamber adapted to carry out pyrolytic conversion of hot gases therein in part to carbon black of good quality, said chamber being directly connected to discharge said hot converted gases into said quench, and a liquid dispenser disposed to spray iiquid into said gases in said quench and thereby check the progress of the reaction and thereby prevent the degradation of end products and creation of unwanted products, the improvement in which said quench comprises a ceramic refractory first conduit section directly connected to said chamber to receive said hot gases therefrom, a heat conducting uninsulated metal second conduit section directly connected to said first section to receive said gases therefrom, said ceramic refractory in said first section being perforated, and said liquid dispenser comprising a metal liquid supply conduit and metal spray head located in said perforation in said perforated ceramic refractory and disposed and directed to spray said liquid through said perforation into and through said first section and out the discharge end thereof into said second section against the wall of said second section without said liquid spray contacting said ceramic refractory, whereby cracking and spalling of said ceramic refractory due to impingement of sprayed liquid on the same is substantially eliminated, and whereby the overall length of said furnace and quench, and thereby the pyrotlytic reaction time therein, is reduced.

3. In the combination of a carbon black furnace and a liquid spray quench, said furnace having a ceramic refractory chamber adapted to carry out pyrolytic conversion of hot gases therein in part to carbon black of good quality, said chamber being directly connected to discharge said hot converted gases into said quench, and a liquid dispenser disposed to spray liquid into said gases in said quench and thereby check the progress of the reaction and thereby prevent the degradation of end products and creation of unwanted products, the improvement in which said quench comprises a ceramic refractory first conduit secton directly connected to said chamber to receive said hot gases therefrom, a heat conducting unin sulated metal second conduit section directly connected to said first section to receive said gases therefrom, said ceramic refractory in said first section being perforated, and said liquid dispenser comprising a metal liquid supply conduit and metal spray head located in said perforation in said perforated ceramic refractory and disposed and directed to spray said liquid through said perforation into and through said first section and out the discharge end thereof into said second section at an angle of from to 875 in a downstream direction from a plane tangent to the surface of said ceramic refractory immediately surrounding said perforation without said liquid spray contacting said ceramic refractory, whereby cracking and sp alling of said ceramic refractory due to impingement of sprayed liquid on the same is substantially eliminated, and whereby the overall length of said furnace and quench, and thereby the pyrolytic reaction time therein, is reduced.

References Cited in the file of this patent UNITED STATES PATENTS 630,506 Hirzel Aug. 8, 1899 692,165 Moore Jan. 28, 1902 907,379 Laurent Dec. 22, 1908 1,874,002 Fantz Aug. 30, 1932 2,140,316 Furlong Dec. 13, 1938 2,143,770 Friauf et al. Jan. 10, 1939 2,368,828 Hanson et al. Feb. 6, 1945 2,387,473 Spitzka Oct. 23, 1945 2,440,424 Wiegand et al. Apr. 27, 1948 2,495,665 Spring Jan. 24, 1950 2,551,789 Copley May 8, 1951 2,558,345 Dickman June 26, 1.951

FOREIGN PATENTS 14,693 Great Britain July 10, 1908 607,296 Great Britain Aug. 27, 1948 

1. IN THE COBINATION OF A FURNACE AND A LIQUID SPRAY QUENCH, SAID FURNACE HAVING A CERAMIC REFRACTORY CHAMBER ADAPTED TO CARRY OUT PYROLYTIC CONVERSION OF HOT GASES THEREIN, SAID CHAMBER BEING DIRECTLY CONNECTED TO DISCHARGE SAID HOT CONVERTED GASES INTO SAID QUENCH, AND A LIQUID DISPENSER DISPOSED TO SPRAY LIQUID INTO SAID GASES IN SAID QUENCH, THE IMPROVEMENT IN WHICH SAID QUENCH COMPRISES A CERAMIC REFRACTORY FIRST CONDUIT SECTION DIRECTLY CONNECTED TO SAID CHAMBER TO RECEIVE SAID HOT GASES THEREFROM, A HEAT CONDUCTING UNINSULATED METAL SECOND CONDUIT SECTION DIRECTLY CONNECTED TO SAID FIRST SECTION TO RECEIVE SAID GASES THEREFROM, SAID CERAMIC REFRACTORY IN SAID FIRST SECTION BEING PERFORATED, AND SAID LIQUID DISPENSER COMPRISING A METAL LIQUID SUPPLY CONDUIT AND METAL SPRAY HEAD LOCATED IN SAID PERFORATION IN SAID PERFORATED CERAMIC REFRACTORY AND DISPOSED AND DIRECTED TO SPRAY SAID LIQUID THROUGH SAID PERFORATION INTO AND THROUGH SAID FIRST SECTION AND OUT THE DISCHARGE END THEREOF INTO SAID SECOND SECTION WITHOUT SAID LIQUID SPRAY CONTACTING SAID CERAMIC REFRACTORY, WHEREBY CRACKING AND SPALLING OF SAID CERAMIC REFRACTORY DUE TO IMPINGEMENT OF SPRAYED LIQUID ON THE SAME IS SUBSTANTIALLY ELIMINATED, AND WHEREBY THE OVERALL LENGTH OF SAID FURNACE AND QUENCH, AND THEREBY THE PYROLYTIC REACTION TIME THEREIN, IS REDUCED. 